ie0c01650_si_001.pdf (1.14 MB)
Operation and Optimization of Microwave-Heated Continuous-Flow Microfluidics
journal contribution
posted on 2020-05-22, 14:33 authored by Tai-Ying Chen, Montgomery Baker-Fales, Dionisios G. VlachosMicrowave
(MW) technology can be powerful for electrification and
process intensification but limited fundamental understanding of scalability
and design principles hinders its effective use. In this work, we
build a continuous-flow microreactor inside a commercial single-mode
MW applicator and the corresponding computational fluid dynamics model
to simulate the temperature profile. The model is in good agreement
with experiments for various microreactor dimensions and operating
conditions. The model indicates that MW heating is greatly influenced
by reactor geometry as well as the operating parameters. We observe
a strong correlation between parameters and develop a gradient boost
regression tree model to predict the outlet temperature accurately.
This model is then applied to optimize the dimensions and operating
conditions to maximize the outlet temperature and energy efficiency,
resulting in a Pareto optimal. We demonstrate computationally and
experimentally that it is possible to surpass the Pareto optimal and
achieve an energy efficiency of ∼90% or greater at temperatures
relevant for liquid-phase chemistry via salting of the solvent. The
present methodology can be applied to other complex MW reactors. The
combined numerical and experimental approach provides insights into
and a framework for scale-up and optimization.